Identification of Deviations Between an Actual System and a Digital Twin

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This patent presents a method and apparatus for automatically identifying differences between a real automated system (such as a factory production line) and its corresponding digital twin. The invention uses a sensor unit attached to a piece of process material, which records various physical parameters as it moves through the real system. These recorded data are then compared in real-time or afterwards against simulated data from the digital twin. If discrepancies are found, the exact location in the real system where the deviation occurs is identified, enabling targeted investigations and corrections.

Use CasesContent extracted from patent full text and abstract with AI.

• Monitoring production lines for deviations from their designed digital twins in real-time.
• Quality assurance in manufacturing plants by automatically detecting implementation or maintenance errors.
• Automated commissioning and maintenance of industrial facilities with minimal manual inspection.
• Support for process optimization by identifying deviations between expected and actual system behaviors.
• Enabling predictive maintenance by timely detection of unexpected changes in automated systems.
• Assisting retrofitting or upgrades of existing installations by highlighting mismatches between reality and modeled expectations.
• Providing a validation tool for systems integrators and simulation experts.

BenefitsContent extracted from patent full text and abstract with AI.

• Automates the identification of differences between physical installations and their digital designs, saving time and labor compared to manual inspections.
• Enables precise localization of deviations, allowing for quicker root-cause analysis and correction.
• Improves overall system reliability and product quality through continuous monitoring and comparison.
• Reduces downtime and operational disruptions by enabling proactive detection and intervention.
• Supports dynamic maintenance and adaptation in response to system changes, expansions, or repairs.
• Facilitates the ongoing alignment of the digital twin with the real system, ensuring digital models remain accurate over time.
• Enhances the accuracy and usefulness of digital twins in industrial applications.

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Patent Abstract

A method and apparatus for determining differences between an automated installation and a digital twin of the automated installation and to an automated installation that includes the apparatus, wherein a sensor unit is fastened to a process material and passes through an automated installation together with the process material where, during this process, the sensor unit continuously records at least one measurement variable, a temporal profile of the recorded measurement variable is compared with a temporal profile of a corresponding simulated measurement variable and if there is a difference between the temporal profiles, then the location in the automated installation at which the difference is present is identified.